Defender 300Tdi (1996+). Manual - part 24

FUEL SYSTEM

ADJUSTMENT

THROTTLE CABLE

Adjust

1. Slacken throttle cable adjustment ferrule.
2. Hold throttle lever in fully closed position.
3. Adjust outer cable, by rotating ferrule, to give

1,57 mm (1/16 in) of deflection in the inner cable.

4. Check that throttle opens fully when the throttle

is depressed.

EGR THROTTLE POSITION SENSOR

Check

1. Run engine until normal operating temperature is

reached.

2. Switch off engine and disconnect throttle position

sensor multi-plug.

3. Connect an Ohmmeter across pins 1 and 3 of

multi-plug. Ohmmeter should read between 1K
and 1.05K ohms.

4. Connect Ohmmeter across pins 1 and 2 of

multi-plug. Ohmmeter should read between 850
and 900 ohms.

5. If readings are correct, reconnect multi-plug.
6. If readings are not obtained slacken 2 torx

screws securing sensor.

7. Rotate sensor to obtain correct Ohmmeter

reading, then tighten torx screws.

8. Re-check readings and fit multiplug.
9. If, after adjustment, Ohmmeter readings cannot

be achieved, fit new sensor.

See Repair, EGR

throttle position sensor

FUEL SYSTEM

ADJUSTMENT

LOW AND HIGH IDLE SPEED ADJUSTMENT

NOTE: The high idle speed (cold start idle)
is automatically set by the setting of the
low idle speed and cannot be adjusted

individually.

1. Check and adjust throttle cable.

See Throttle

cable

2. Start engine and run it until normal operating

temperature is reached.

3. Using a suitable tachometer, check the engine

idle speed,

See ENGINE TUNING DATA,

Information, 300Tdi

4. If adjustment is necessary, first slacken the

locknut on injection pump.

5. Turn adjustment screw clockwise to increase

engine speed or anti-clockwise to decrease the
speed. Run engine at an increased speed for a
few seconds then check idle speed again.

6. When correct speed has been achieved, hold

adjuster screw steady while tightening locknut.

NOTE: The low idle speed control is the
only permitted adjustment in service. Any
additional adjustments required must be

entrusted to authorised Bosch agents.

THROTTLE PEDAL ADJUSTMENT

Adjust

1. First ensure that throttle cable is correctly

adjusted

See Throttle cable

2. Depress throttle pedal, by hand, to full extent of

injection pump lever travel. Slacken locknut and
adjust throttle pedal stop screw to take up
clearance between screw and bulkhead. Ensure
no strain is placed upon throttle cable and pump
lever.

3. Retighten locknut.

FUEL SYSTEM

ADJUSTMENT

INJECTION PUMP TIMING - CHECK AND ADJUST

Service repair no - 19.30.01

1. Viewing the valve mechanism through oil filler

aperture, turn crankshaft clockwise until inlet
valve of No.1 cylinder has just closed. No.1
cylinder is now just before TDC.

2. Remove blanking plug from flywheel housing

and insert timing tool LRT-12-044, locating
centre pin on flywheel.

NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis

adjustments or remove and refit procedures are
required, it may be necessary to remove the
undertray and/or integral access panels.

See

CHASSIS AND BODY, Repair, Front undertray or
See CHASSIS AND BODY, Repair, Rear undertray

3. Cearfully rotate crankshaft clockwise until centre

pin engages timing slot in flywheel.

4. Remove injection pump access plate, complete

with gasket, from front cover plate.

5. Fit locking pin LRT-12-045/2 to injection pump

gear. If difficulty is experienced in inserting pin,
adjustments will be needed to correctly set
injection pump timing as follows:

6. Support injection pump retaining nut to prevent

strain on timing belt.

7. Slacken the 3 keeper plate retaining bolts.
8. Carefully turn fixing nut and keeper plate until

locking pin can be inserted, without restriction,
into injection pump gear.

9. Tighten keeper plate bolts to

25 Nm (18 lbf/ft)

and remove locking pin.

10. Refit injection pump access plate plate and

gasket.

11. Remove flywheel timing tool and refit blanking

plug.

12. Run engine until normal operating temperature is

reached and check that idle speed adjustment,
See low and high idle speed adjustment and
throttle cable adjustment

See Throttle cable

are correct.

FUEL SYSTEM

ADJUSTMENT

TURBOCHARGER BOOST PRESSURE - CHECK

Service repair no - 19.42.06

1. Disconnect actuator hose from turbocharger and

insert a suitable ’T’ piece connector.

2. Connect a short length of suitable hose to

turbocharger and ’T’piece.

3. Connect further hose to ’T’ piece and pressure

gauge LRT-12-011. The pressure gauge hose
must be long enough to reach into the vehicle
cab so that the gauge can be observed by driver
or passenger.

4. To check maximum boost pressure, drive

vehicle normally, but in such a manner that full
throttle can be maintained whilst climbing a hill
with engine speed held steady between 2,500
and 3,000 rev/min. Under these circumstances
boost pressure should read 0,95 - 1,09 Kgf/cm

(13.5 - 15.5 lb/in

PRIMING THE FUEL SYSTEM

Service repair no - 19.50.01

NOTE: If the fuel system has been
completely drained carry out the
procedures for priming both the

sedimentor, if fitted, and fuel filter and injection
pump.

Sedimentor and fuel filter

If the sedimentor or fuel filter have been dismantled
and air has entered the fuel system carry out the
following procedure:

1. Slacken fuel filter bleed screw.
2. Operate hand priming lever on fuel lift pump until

fuel, free from air, emerges from filter.

NOTE: Ensure that the fuel pump lever is
on the bottom of operating cam when
priming, otherwise maximum movement of

the lever cannot be achieved.

3. Tighten filter bleed screw whilst fuel is still

emerging.

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